101601-5581 ZEXEL 9 400 614 620 BOSCH INJECTION-PUMP ASSEMBLY 9400614620 1016015581 220006380a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 620 9400614620

ZEXEL 101601-5581 1016015581

HINO 220006380A 220006380a

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Buy INJECTION-PUMP ASSEMBLY 101601-5581 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-5581 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9931

3. GOVERNOR 105921-3580

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0581

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7690

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6(220)

13. NOZZLE-HOLDER 105030-4170

14. NOZZLE 105015-7580

15. NOZZLE SET

Include in #1:

101601-5581 as INJECTION-PUMP ASSEMBLY

104303-2550 as _

Cross reference number

BOSCH 9 400 614 620 9400614620

ZEXEL 101601-5581 1016015581

HINO 220006380A 220006380a

Zexel num

Bosch num

Firm num

Name

101601-5581

9 400 614 620

220006380A HINO

INJECTION-PUMP ASSEMBLY
W06E * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-5720

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.1 3.07 3.13

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 9.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 48.9 46.9 50.9

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 8.3+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 7 5.5 8.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.4)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 48.9 47.9 49.9

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 51.3 47.3 55.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 35.9 31.9 39.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1(9.4)

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 52.1 48.1 56.1

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position (R1+0.45 )

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 31.4 27.4 35.4

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 111 101 121

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1330--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1280

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 4.5 4.2 4.8

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=E04
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=37deg+-5deg b=39deg+-3deg

Stop lever angle

N:Engine normal (pump normal) S:Engine stop (1)Set the stopper screw. (2)(Apply red paint after setting.)
----------

----------
a=20deg+-5deg b=29.5deg+-5deg

0000001501 LEVER

(N) Engine normal (pump normal) (S) Engine stop (A) stopper screw (B) Stop direction (perpendicular) Stop lever adjusting procedure (1)After completing adjustment, confirm that the engine's normal lever angle (pump's normal lever) is within the specifications in the figure above. (2)With the speed lever at Full and the pump speed at Na (specified speed), temporarily set the stopper screw (A) at the rack position Ra. (3)Turn the stopper screw (A) Rb in the stop direction (Nb turns) and set it. Measure the rack position. (Rack position = approx. Rc) (4)After setting, confirm non-injection with the speed lever at idle and pump speed at Nc. (5)After adjustment, apply red paint.
----------
Na=1750r/min Ra=5.2mm Rb=1.5mm Nb=1.5 Rc=3.2mm Nc=250r/min
----------
ra=37mm a=20deg+-5deg b=29.5deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

Information:

Storage Procedure
When a generator is in storage for any length of time, moisture condenses in the windings. Minimize the condensation by use of a dry storage space and space heaters. Refer to step 2 belowIf a brush-type generator (SRCR) is to be in storage for a year or more, lift the brushes off the slip ring to prevent damage to the slip ring by chemical action.After Storage
Test the main stator windings with a megohmmeter in the following situations: 1. Before initial startup of generator set.2. Every 3 months* if generator is operating in a humid environment.3. If generator has not been run under load for 3 months* or more.*This is a guideline only. It may be necessary to megger more frequently if environment is extremely humid, salty or if the last megger test was close to 1 megohm.The megohmmeter test is described in Service Manuals SENR2180 or SENR7968. A reading of 1 meghom or less indicates that the winding has absorbed too much moisture.To Remove Moisture
To remove moisture caused by high humidity, use one of the following methods to make the generator dry:1. Energize space heaters in generator if so equipped.2. Put the generator in an oven at a temperature of not more than 85°C (185°F) for four hours.
If an oven is used for drying, use a forced air type rather than a radiant type. Radiant ovens can cause localized overheating.
3. Space heaters of the same type used in marine applications, can be installed on generators. (See the Parts Book.) These heaters heat the windings to remove moisture and should be connected at all times in high humidity conditions whenever the generator is not running.4. Use a canvas enclosure around the generator and heating lamps to increase the temperature. Make an opening in the top for release of moisture.5. Send a low voltage current through the windings to increase the temperature of the windings. Do not exceed 85°C (185°F).If the megohmmeter test reads under 1 megohm after the drying or if it goes below 1 megohm shortly after drying, contact your Caterpillar dealer. The insulation has deteriorated and should be reconditioned.